ACV HeatMaster TC INSTALLATION OPERATING AND SERVICING INSTRUCTIONS

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Installation, Operating and

Servicing Instructions

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INDEX

WARNINGS	3
Who should read these instructions	3
Symbols	3
Recommendations	3
Applicable standards	3
Warnings	3

INTRODUCTION	4
Totally condensing	4
Operating mode	4
Description of the specifications	6
Production of hot water	6
Frost protection	6

USERS GUIDE	7
Direction for use	7
Settings parameters	7

TECHNICAL CHARACTERISTICS	9
Gas categories	9
Maximum operating conditions	10
Domestic hot water features	10

ELECTRICAL CONNECTION	11
Wiring diagram	11

INSTALLATION INSTRUCTIONS	12
Dimensions	12
Hydraulic connections	12
Boiler room	12

INSTALLATION	13
Connection to the chimney	13
Connection to the gas	15
Domestic hot water connection	15
Heating connections	16
Installation of a single high temperature circuit with room thermostat ACV 15 control	17
Installation of a weather depending heating circuit high or low temperature	18
Installation of two heating circuit controlled by control unit and ZMC-1 module	20

COMMISSIONING AND MAINTENANCE	22
Commissioning the system	22
Inspection and maitenance	22
Temperature sensor resistance tables	22
Disassembling the burner	23
Disassembling and checking the electrode	23
Cleaning the heat exchanger	23

MCBA PARAMETERS FOR THE SPECIALIST	24
Standby mode	24
Setting the MCBA parameters	25
Request for information on the installation	26
Entering the code	26
MCBA parameters with code restricted access	27
Communication mode	30
Error mode	30
Safety stop [error mode]	31

SPARE PARTS	See at the end of this manual

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WHO SHOULD READ THESE INSTRUCTIONS

These instructions should be read by:

-the specifying engineer

-the installer

-the user

-the service engineer

SYMBOLS

The following symbols are used in this manual:

Essential instruction for the correct operation of the installation.

Essential instruction for the safety of persons and the environment.

Danger of electrocution.

WARNINGS

•Specific regulation applicable in Belgium:

The CO2 level, the air and gas flows and the gas / air ratio are factory set . Any field adjustments of those settings is not allowed in Belgium.

•It is important to switch the boiler off before carrying out any work.

•There are no user accessible parts inside the boiler casing.

APPLICABLE STANDARDS

The appliances carry the CE mark in accordance with the standards in force in the various countries (European Directives 92/42/EC “Efficiency”, 90/396/EC “Gas appliances”).

They also carry the “HR-TOP” label (Gas condensation boilers).

Risk of scalding.

RECOMMENDATIONS

•Please, carefully read this manual before installing and commissioning the boiler.

•It is prohibited to carry out any modifications to the inside of the appliance without the manufacturer’s prior and written agreement.

•The product must be installed and serviced by trained engineers, in compliance with current standards.

• Any failure to follow instructions relating to tests and test procedures may result in personal injury or risks of pollution.

•To guarantee safe and correct operation of the appliance, it is important to have it serviced and maintained every year by an approved installer or maintenance company.

•In case of anomaly, please call your service engineer.

•Despite the strict quality standards imposed by ACV during the manufacture, inspection and transport of its appliances, you might notice some errors. Please report immediately any fault to your approved installer. Remember to note the fault code displayed on the screen.

•The parts may only be replaced by genuine factory parts. You will find a list of the spare parts and their ACV reference number at the end of this document.

•The burners are preset in our factory for use with natural gas [equivalent to G20].

WARNINGS

IF YOU SMELL GAS:

-Immediately isolate the gas supply.

-Open windows and doors to ventilate the area.

-Do not use any electrical appliances and do not operate any switches.

-Immediately notify your gas supplier and/or your installer.

This documentation is part of the information delivered with the appliance and must be given to the user and stored in a safe place!

An approved installer must carry out the assembly, commissioning, maintenance and repair of the system, in accordance with current standards in force.

ACV shall not accept any responsibility for damage caused by non-compliant location of the system or by use of the parts or connections not approved by ACV for this application.

The manufacturer reserves the right to change the technical characteristics and specification of its products without notice.

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INTRODUCTION

TOTALLY CONDENSING :

The HeatMaster® TC combines the unique ACV Tank-in-Tank concept with a dual primary circuit resulting in exceptional performance from a totally condensing combination boiler.

Tank-in-Tank technology

ACV’s advanced implementation of thermal storage technology is tried and tested and is remarkably simple, efficient and reliable. At the heart of the HeatMaster® TC is a stainless steel tank through which the flue tubes pass.

This is surrounded by a mild steel shell containing the primary water, which extends down to the combustion chamber and even around the flue tubes. The burner fires onto the primary water which indirectly heats the stainless steel tank containing the hot water. As with all Tank-in-Tanks, this is corrugated over its full height and is suspended in the HeatMaster® TC by its hot and cold water connections.

The area of the heat transfer surface is therefore much greater than that of standard direct fired water heaters. A much larger heat transfer surface means that Tank-in-Tank units recover much faster than any other kind of hot water storage device - and keeps boiler cycling to a minimum. The high storage temperature within the inner tank also results in exceptional hot water outputs.

Dual primary circuit technology

The HeatMaster® TC primary circuit is split into two sections - a high temperature upper circuit and a low temperature lower circuit, divided by a separation plate. The hot water storage

tank	is located in the upper circuit which always operates
at a	temperature of between 60°C and 90°C. This is ideal

for hot water production as it maintains the stored water at constantly high temperatures, eliminating bacterial formation such as Legionellae, as well as resulting in high volume hot water production.

The down-firing flue tubes pass through the upper circuit, through the separation plate and into the lower circuit. The primary water here operates at a temperature typically between 30°C and 60°C for heating (dependent on the heating return temperature), perfect for condensing when working in heating mode.

Operating modes

In both heating and hot water modes, the premix gas burner fully modulates the power to match the system demand.

1 Heating

The heating return enters the lower circuit of the boiler, which allows the boiler to operate in condensing mode.

The upper circuit of the

HeatMaster® TC is kept at a consistently high temperature due to the internal shunt pump which ensures that the primary water circulates around the heat exchanger flue tubes.

2 Hot water

With the upper circuit maintained at high temperature, the

HeatMaster® TC is always ready to supply hot water on demand.

The cold water enters through the indirect water preheater at the base of the heat exchanger and is preheated before entering the hot water tank.

The low temperature of the bottom circuit results in continuous condensation of the flue gases in hot water mode.

Dual domestic hot water tank technology

During hot water mode, the bottom circuit operates at a much lower temperature, typically 5°C to 20°C depending on the cold water inlet temperature. The incoming cold water enters the lower primary circuit via an indirect water preheater.

As this preheater is wrapped around the lower flue tubes of the combustion chamber, it is able to absorb the remaining heat from the flue gases. The result is that during hot water mode the HeatMaster® TC totally condenses whether on full or part-load.

3	Heating and
	hot water

Once up to temperature, the HeatMaster® TC is capable of producing heating and hot water simultaneously.

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INTRODUCTION

HeatMaster® 35 TC

1.Flue connection concentric Ø 80/125 mm convertible to parallel connection Ø 80/80 mm.

2.Domestic hot water outlet

3.Heating flow

4.Stainless steel heat exchanger

5.Stainless steel Tank-in-Tank hot water store

6.Indirect water preheater

7.Heating return

8.Cold water inlet

9.Condenstrap

10.Modulating premix gas burner

11.Gas connection

12.Combustion chamber

13.Control panel

14.Primary heating circuit

15.Polyurethane foam insulation

16.Boiler shunt pump

17.Separation plate

18.Primary safety valve (3 bar)

19.Drain cock

HeatMaster® 85 TC

1.Flue connection concentric Ø 100/150 mm convertible to parallel connection Ø 100/100 mm

2.Domestic hot water outlet

3.Heating flow

4.Combustion chamber

5.Stainless steel heat exchanger

6.Stainless steel Tank-in-Tank hot water store

7.Auxiliary tank primary return

8.Indirect water preheater

9.Heating return

10.Cold water inlet

11.Separation plate

12.Gas connection

13.Modulating premix gas burner

14.Control panel

15.Primary heating circuit

16.Primary expansion vessel (2x)

17.Polyurethane foam insulation

18.Boiler shunt pump

19.Primary safety valve (3 bar)

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INTRODUCTION

DESCRIPTION OF THE SPECIFICATIONS

The HeatMaster® TC is an hot water producer combined in a condensing boiler in accordance to the Belgium "HR-Top" standard. The boiler is certified compliant with "CE" standards as a connected appliance C13(x) - C33(x) - C43(x) - C53 - C83(x), but it can also be connected as an open appliance in category B23 or as an appliance of category B23P, which can operate with a positive pressure.

Lining

The boiler is protected by a steel lining that first of all undergoes a degreasing and phosphation process before being lacquered and heated at 220°C. The inside of this lining is coated with a layer of thermal and acoustic insulation, reducing losses to a minimum.

Heat exchanger

The core of the HeatMaster® TC features a new stainless steel heat exchanger. This piece of technology represents the fruit of exhaustive research and intensive laboratory testing. It reflects ACV’s eighty years of experience in using stainless steel for heating and hot water functions. The particular geometry of the exchanger pipes is calculated to obtain a very large Reynolds number throughout its cycles.

The HeatMaster® TC achieves an exceptional output that remains stable throughout the boiler’s life, given that it causes no oxidation on the exchanger, which is manufactured entirely from quality steel.

Burner

ACV uses its BG 2000-M burner for the HeatMaster® TC: this is an air/gas premix burner providing safe and silent operation while limiting emissions (NOx and CO) to an incredibly low level. Although the ACV BG 2000-M boiler is very modern, it uses proven technology and is manufactured from standard spare parts that are easily available on the market.

Temperature regulation

The basic version of the HeatMaster® TC is fitted with a microprocessor controlled regulator (MCBA) which takes over both the safety functions (ignition, monitoring the flame, limiting the temperature, etc.) and control of the boiler temperature.

This MCBA also includes a weather-dependent regulator. All you need to do is connect the outdoor temperature sensor available as an option to the device. However, this regulator can also operate with a standard ON/OFF room thermostat In addition, with the combination of a weather-dependent regulator and a room thermostat, you can control the temperatures based on the weather with compensation for the indoor temperature.

There are four user adjustable parameters. By entering a special maintenance code, qualified installers can access several other parameters to adapt the boiler to special requirements. In principle, these parameters are factory set for all normal applications.

PRODUCTION OF HOT WATER

In addition to its exceptional hot water performances, the ACV Tank-in-Tank concept provides the follwoing advantages :

-A solution for scale deposits: thanks to the specially designed corrugations, the hot water tank expands and contracts during the heating cycle, preventing the formation of scale.

-A guarantee against the risk of Legionnellae Disease and bacteria: the hot water tank is fully immersed in the primary circuit and the hot water is constantly kept at a temperature above 60°C.

-Exceptional resistance against corrosion and aggression: provided by the stainless steel.

FROST PROTECTION

The boiler is equipped with an integrated frost protection: as soon as the boiler temperature drops below 7°C, the system activates the central heating pump. As soon as the NTC1 flow temperature drops below 3°C, the system automatically ignites the burner until the temperature rises above 10°C. The pump continues to run for about 10 minutes.

If an outdoor temperature sensor is connected to the system, the pump is activated as soon as the outside temperature drops below the specified threshold.

To provide efficient protection for the whole system against frost, all the valves on the radiators and the convectors should be completely open.

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USERS GUIDE

DIRECTIONS FOR USE

SETTINGS PARAMETERS

Your system must be checked once a year by an approved installer or maintenance company.

Starting the burner

During operation, the burner starts automatically as soon as the boiler temperature drops under the required set point and it stops as soon as the boiler reaches that temperature.

Control panel

	2
1	bar 3
O	4
Pre-cut for an optional
Control Unit controller
MCBA display
Pressure gauge
ON/OFF switch

Summer/Winter switch

Heating system

The central heating circuit must be pressurized (see in the chapter “Installation” how to define the system pressure).

The pressure indicator is located on the right-hand side of the display.

If your system needs to be refilled more than twice a year, please contact your installer.

The CH pressure must be a minimum of 1 bar and must be checked by the end user on a regular basis. If the pressure drops under 0.5 bar, the integrated water pressure switch blocks the appliance until the pressure in the system returns to a level above 0.8 bar. The connection for a fill valve is provided underneath the appliance. The installer can also fit the system with a separate valve. Make sure that the appliance is powered off when filling the system. To do this, toggle the Start/Stop switch located on the left of the screen to Off. (see the Control panel).

For more information, please ask your installer when the system is delivered.

A safety valve is provided at the underneath of the appliance.

If the system pressure exceeds 3 bars, this valve opens and drains the water from the system. In this case, please contact your installer.

Setting the domestic hot water temperature:

(Hot water temperature)

-Press Mode: The screen displays PARA.

-Press Step: the first character is 1 and the last two characters give the current hot water temperature setting.

-To change this temperature, press + or - until the last two digits show the desired temperature value.

-Press Store to save the new temperature setting.

-Press Mode twice to return to Pilot mode (normal operating mode).

Enabling or disabling the hot water heating mode:

(hot water)

-Press Mode: The screen displays PARA.

-Press Step twice: the first character is 2 and the last two characters give the current setting:

00 = disabled; 01 = enabled.

-To change this parameter, press + or - until the screen displays the desired value:

00 = disabled; 01 = enabled.

-Press Store to save.

-Press Mode twice to return to Pilot mode (normal operating mode).

Enabling or disabling Central Heating mode:

(heating)

-Press Mode: The screen displays PARA.

-Press Step three times: the first character is 3 and the last two characters give the current setting:

00 = disabled; 01 = enabled.

-To change this parameter, press + or - until the screen displays the desired value:

00 = disabled; 01 = enabled.

-Press Store to save.

-Press Mode twice to return to Pilot mode (normal operating mode).

Setting the central heating temperature:

(maximum temperature for the heating circuit)

-Press Mode: The screen displays PARA.

-Press Step four times: the first character is 4 and the last two characters give the current central heating temperature setting.

-To change this temperature, press + or - until the last two digits show the desired temperature value.

-Press Store to save the new temperature setting.

-Press Mode twice to return to Pilot mode (normal operating mode).

Fault:

The temperature setting for the appliance and the safety functions for its various parts are continuously monitored by a regulator controlled by a microprocessor (the MCBA). In the event of a fault, this MCBA disables the appliance and displays an error code: the screen flashes displaying E as the first character, followed by the error code.

To reset the appliance:

-Press "Reset" on the screen.

-Contact your installer of the fault happens again.

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TECHNICAL CHARACTERISTICS

		HeatMaster® 35 TC		HeatMaster® 85 TC
Central heating		Natural gas	Propane	Natural gas	Propane

Max. Input 80/60°C	kW	34,9	30,6	85,0 [92,0]	85,0 [92,0]

Min. Input 80/60°C	kW	10,0	10,0	17,2	17,2

Max. output 80/60°C	kW	34,1	29,9	82,5	82,5

Min. output 80/60°C	kW	9,8	9,8	16,7	16,7

Efﬁ ciency 30% load [EN677]	%	108,5	108,5	107,8	107,8

Efﬁ ciency domestic hot water mode [ t = 30°C]	%	105,9	105,9	104,0	104,0

Flue gases

CO emissions max. / min. Input	mg/kWh	70 / 6	105 / 17	58,9 / 4,3	90,0 / 45,0

NOx emissions max. / min. Input	mg/kWh	59 / 29	72 / 31	72,4 / 19	85 / 27

NOx classiﬁ cation [EN483]		5	5	5	5

Flue gas temperature — max. Input 80/60°C	°C	60	60	61,6	61,6

Flue gas temperature — max. Input 50/30°C	°C	32	32	35,1	35,1

Mass ﬂ ow rate of combustion products	kg/h	55	46,5	137 [148]	134 [145]

Flue gas pipe - Max. pressure drop	Pa	130	130	150	150

Concentric ﬂ ue gas channel maximum length	m	20	20	20	20

Gas

Gas pressure	mbar	20 / 25	30 / 37 / 50	20 / 25	30 / 37 / 50

G20 gas ﬂ ow rate	m3/h	3,7	—	8,99 [9,73]	—
G25 gas ﬂ ow rate	m3/h	4,3	—	10,46 [11,32]	—
G31 gas ﬂ ow rate	m3/h	—	1,25	—	1,25
CO2 max. Input	% CO2	9,4	10,5	9,3	10,9

CO2 min. Input	% CO2	9,0	10,1	8,6	9,0

Hydraulic parameters

Max. operating temperature	°C	90	90	90	90

Total capacity	L	189	189	315	315

Heating circuit capacity	L	108,5	108,5	125	125

Maximum operating pressure central heating	bar	3	3	3	3

Heat exchanger pressure drop [ T = 20°C]	mbar	30	30	200	200

Electrical connection

Class	IP	30	30	30	30

Supply voltage	V/Hz	230/50	230/50	230/50	230/50

Maximum absorbed electrical power	A	0,8	0,8	1,0	1,0

Weight empty	kg	174	174	284	284

[…] = Domestic hot water mode

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TECHNICAL CHARACTERISTICS

Gas categories HeatMaster® 35 / 85 TC

		I2E(S)B *	II2H3B/P	II2H3P	II2E3B/P	II2Er3P	II2L3B/P	II2L3P	I3P
		I2E(R)B **

	G20	20 mbar	20 mbar	20 mbar	20 mbar	20 mbar

	G25	25 mbar				25 mbar	25 mbar	25 mbar

	G30		30 - 50 mbar		30 - 50 mbar		30 - 50 mbar

	G31		30 - 50 mbar	37 - 50 mbar	30 - 50 mbar	37 - 50 mbar	30 - 50 mbar	37 - 50 mbar	37 mbar

BE	Belgium

CH	Switzerland

CZ	Czech republic

DE	Germany

DK	Denmark

EE	Estonia

ES	Spain

FR	France

GB	Great Britain

GR	Greece

IE	Ireland

IT	Italy

LU	Luxembourg

LT	Lithuania

NL	Netherlands

PL	Poland

PT	Portugal

SI	Slovenia

SK	Slovakia

SE	Sweden

(*) HeatMaster ® 35 TC		(**) HeatMaster ® 85 TC

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MAXIMUM OPERATING CONDITIONS

Maximum service pressure (tank full of water) - Primary circuit : 3 bar

- Secondary circuit : 10 bar

Maximum operting temperature : 90°C

Water quality:

-Chlorures : < 150 mg/L

-6 ≤ PH ≤ 8

DOMESTIC HOT WATER FEATURES

			HeatMaster®	HeatMaster®
Operating conditions at 90°C			35 TC	85 TC
Operating conditions at 90°C

Peak ﬂ ow at 40°C [	T = 30°C]	L/10’	472	868

Peak ﬂ ow at 40°C [	T = 30°C]	L/60’	1322	3076

Constant ﬂ ow at 40°C [ T = 30°C]		L/h	1070	2713

Peak ﬂ ow at 45°C [	T = 35°C]	L/10’	389	718

Peak ﬂ ow at 45°C [	T = 35°C]	L/60’	1116	2513

Constant ﬂ ow at 45°C [ T = 35°C]		L/h	917	2325

Peak ﬂ ow at 60°C [	T = 50°C]	L/10’	243	413

Peak ﬂ ow at 60°C [	T = 50°C]	L/60’	731	1594

Constant ﬂ ow at 60°C [ T = 50°C]		L/h	642	1617

Pre-heat time		minutes	37	35

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ACV HeatMaster TC INSTALLATION OPERATING AND SERVICING INSTRUCTIONS

ELECTRICAL CONNECTION

WIRING DIAGRAM : HeatMaster® TC

1.	Power supply 230 V	13.	NTC2 return sensor
2.	ON/OFF switch	14.	NTC5 flue gas temperature
3.	Boiler shunt pump	15.	Room thermostat (optional)
4.	Heating pump (optional)	16.	NTC3 domestic hot
5.	Gas valve rectifier	17.	NTC4 outdoor temperature (optional)
6.	230Volt - 24Volt transformer	18.	NTC6 second heating circuit flow sensor (optional)
7.	MCBA	19.	Zero volt of 24V circuit.
8.	Display	20.	Safety contact thermostat RAM (optional)
9.	Water pressure switch	21.	Ionisation and ignition cable
10.	Fan PWM control	22.	Burner power supply 230 V (only HeatMaster® 85 TC]
11.	Summer/Winter switch	23.	Gas pressure switch HeatMaster® 85 TC
12.	NTC1 flow sensor

X11.

X5.1

X5.2

BUS A

X5.3

BUS B

X5.4

X4.1

X4.2

X4.3

X3.1

X3.2

X3.3

X3.4

X3.5

X3.6

Blue

X2.1

Bk.

Black

X2.2

Br.

Brown

Grey

X2.3

Or.

Orange

X2.4

Red

X2.5

Violet

X2.6

White

X2.7

Y/Gr.

Yellow/Green

X2.8

X2.9

X2.10

X2.11

X2.12

X12.

Y/Gr

X1.6

X10.7

X1.5

X10.6

X1.4

Y/Gr

X1.3

X10.1

230V

X1.2

X10.3

X1.1

Y/Gr

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INSTALLATION INSTRUCTIONS

DIMENSIONS

HM 35 TC

1720

600

500

125

140

1700

670

110

100

200

960

—

170

230

HM 85 TC

2145

690

580

100

150

160

2095

725

125

105

270

1210

200

235

240

HYDRAULIC CONNECTIONS

HeatMaster ® 35 TC

HeatMaster ® 85 TC

Heating connection [F]

1"1/2

Domestic hot water connection [M]

1"1/2

Gas connection [M]

3/4"

	H
F	I
F
	J
	K
	L
	G
	M
	N
	O

Kit “Easy Fit” only for

HeatMaster ® 35 TC

3 x 65	690
180		730

1736

BOILER ROOM

-Make sure that all air vents are unobstructed any times.

-Do not store any flammable products in the boiler room.

-Do not store any corrosive products, paint, solvents, salts, chlorine products and other detergent products near the appliance.

-If you smell gas, do not switch on any lights, turn off the gas tap at the meter, ventilate the rooms and contact your installer.

ACCESSIBILITY

The appliance must be positioned in such a way to be accessible any time. In addition, the following distances are required around the appliance.

Min. 25 mm	300 mm	Min. 25 mm
	Min.

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CONNECTION TO THE CHIMNEY

-The chimney connections must comply with the applicable standards (in Belgium: NBN D51-003), the local energy supplier’s instructions, the fire regulation and neighbourhood good practices.

-The HeatMaster® TC has an inbuilt gas/air ratio regulator, which makes it largely independent of the pressure drop in the air intake and flue gas extraction system. However, the maximum pressure drop for this system may not be exceeded, or the pressure will diminish. Nevertheless, the gas/air ratio regulator continuously guarantees optimum combustion with very low emission levels.

-The horizontal flue gas pipes must always be installed with a min. slope of 5 mm per meter, upwards from the boiler side.

-There must be no obstruction or openings for any other appliances within a radius of 0.5 metres around the flue terminal of the HeatMaster® TC.

-The maximum flue resistance is 130 Pascal for the HeatMaster® 35 TC and 150 Pascal for the HeatMaster® 85 TC. You can use the following table as the basis for calculating this value (please also refer to the specimen calculation presented under the table).

Sample calculation:

The diagram below consists of the following parts: pipe with monitoring section + 2 * 90° pipe bends + 2 metres of horizontal pipe + 2 * 45° pipe bends + (2 + 1 + 1) metres of vertical pipe and fall back + discharge.

Therefore, the resistance of this system is as follows:

2.5 + (2 x 6.0) + (2 x 5.0) + (2 x 4.0) + (4 x 5.0) + 20 = 72.5 Pa.

This value is less than the maximum authorised resistance, therefore the installation is compliant.

INSTALLATION

Table of flue resistance in Pascal

(1 Pascal = 0,01 mbar)

	Pipe		Air inlet		Air extraction
	concentric		separate		separate

	HM	HM	HM	HM	HM	HM
	35 TC	85 TC	35 TC	85 TC	35 TC	85 TC
	Ø 80/125	Ø 100/150	Ø 80	Ø 100	Ø 80	Ø 100
	mm	mm	mm	MM	mm	mm

1 m	5.0	13,5	1.5	4,1	2.0	5,5
straight pipe	5.0	13,5	1.5	4,1	2.0	5,5
straight pipe

Pipe with a
monitoring	2.5	6,8	—	—	1.0	2,7
section

90° pipe bend	6.0	16,4	1.9	5,2	3.4	9,3

45° pipe bend	4.0	10,9	1.3	3,5	2.3	6,3

Vertical pipe	20.0	54,5	—	—	—	—

Horizontal pipe	15.0	40,9	—	—	—	—

This table is based on the equipment offered by ACV and cannot be applied generally.

mm 1000

1000	mm

2000 mm

mm 2000

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